Curtain wall installation bracket

ABSTRACT

A support bracket for supporting a horizontal mullion during the construction of a curtain wall, the support bracket having a first horizontal leg and a second vertical leg in 90 degree relationship to each other, the horizontal leg defined by a support member engagable with the vertical mullion, the horizontal leg defined by a support member engagable with the horizontal mullion, there being a bracing member angularly secured between the vertical leg and the horizontal leg, the vertical and horizontal legs snap fitting or clamped to the respective horizontal mullion and vertical mullion to maintain the horizontal mullion in non-sagging relationship until it can be secured at its second end.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to curtain walls which are typically constructed with horizontal and vertical support members formed out of extruded aluminum and are erected in order to support glass panels or other panel material between the intersecting horizontal and vertical support members, the present invention relating to a support bracket used in the installation of the horizontal support members.

2. Description of the Prior Art

Curtain walls are widely used in the construction industry. They may be used to support glass panels or possibly decorative panels. A curtain wall can be one story high or several stories high. Typically the curtain wall is constructed with a plurality of vertical support members and interconnecting horizontal support members. The support members are typically made out of extruded aluminum and have a baked on aesthetic finish or an anodized metallic finish.

In the trade, the vertical support member is typically referred to as a vertical mullion and the horizontal support member is referred to as a horizontal mullion. In one installation method, commonly known as the “Stick” method, in which all verticals and horizontals are sent to the job site (knocked down), a first vertical mullion is positioned and secured. On its lateral faces there will be installed, or will have been installed, a plurality of shear blocks consisting of an extruded aluminum block which is secured to the lateral face or faces of the vertical mullion, the cross section of the vertical shear block conforming to the internal cross section of a horizontal mullion. A first end of a horizontal mullion is then secured to the shear block. Depending upon the height of the curtain wall, there may be a plurality of horizontal mullions secured to a plurality of shear blocks at spaced apart distances. Once the first end of the horizontal mullions have been secured to their respective shear blocks, the second adjacent vertical mullion is positioned or secured with its own set of complimentary shear blocks to accommodate the second ends of the horizontal mullions. The installers must then match up the second end of the horizontal mullion with the appropriate shear block and secure same. Once all of the horizontal mullions between the two adjacent vertical mullions are secured, depending upon the width of the curtain wall, the installers will then secure a second set of horizontal mullions to the opposing face of the second vertical mullion and proceed as described until the entire width of the curtain wall is installed.

The difficulty with this procedure arises when the horizontal mullions are of a length which causes the horizontal mullion to sag and place excessive load or stress on the shear block before it can be connected to the second shear block. Horizontal mullions of relatively short distance do not weigh enough to cause the sag, but a horizontal mullion of any significant distance (3 ft or more) causes sag which misaligns the first end of the mullion which is already secured to a shear block and makes it difficult to align the second end of the horizontal mullion to the second shear block. This requires additional work on the part of the installers and oftentimes requires additional man power since you must have someone hold the end of the horizontal mullion so that it does not sag until it can be secured to the second shear block.

In one version of curtain walls, particularly multi-story curtain walls, both the vertical mullion and the horizontal mullion are formed with a complimentary nose portion on the same side of the mullion such that when the complete curtain wall is erected, the intersecting nose portions define a spacial area for the receipt of glass or decorative panels. In another version of a curtain wall, only the horizontal mullion is formed with a nose portion and the vertical mullion has no nose portion. In still another version of a curtain wall used primarily for store fronts and the like where the height is not that great, the horizontal and vertical mullions are formed with no nose portions and the glass or decorative panel is supported on the upper surface of the horizontal mullion and secured to the vertical mullion by a clip means.

Due to the substantial uniformity in the fabrication of vertical and horizontal mullions and curtain walls, Applicant has developed a support bracket which is easily used in the positioning of horizontal mullions and the support of the horizontal mullion until the second end of the horizontal mullion can be secured to its respective shear block.

OBJECTS OF THE INVENTION

An object of the present invention is to provide for a novel support bracket for support of a horizontal mullion in the erection of a curtain wall to prevent sagging and aid in alignment of the horizontal connections during installation.

Another object of the present invention is to provide for a novel support bracket for a horizontal mullion of a curtain wall which provides support until the horizontal mullion can be secured at both ends.

An object of the present invention is to provide for a novel support bracket which snap fits or clamps into position to support a horizontal mullion during installation of a curtain wall.

A still further object of the present invention is to provide for a novel support bracket which is reversible and can support a horizontal mullion from either the right end or left end during the construction of a curtain wall.

SUMMARY OF THE INVENTION

A support bracket for supporting a horizontal mullion during the construction of a curtain wall, the support bracket having a first horizontal leg and a second vertical leg in 90 degree relationship to each other, the horizontal leg defined by a support member engagable with the vertical mullion, the horizontal leg defined by a support member engagable with the horizontal mullion, there being a bracing member angularly secured between the vertical leg and the horizontal leg, the vertical and horizontal legs snap fitting or clamped to the respective horizontal mullion and vertical mullion to maintain the horizontal mullion in non-sagging relationship until it can be secured at its second end.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other objects of the present invention will become apparent, particularly when taken in light of the following illustrations wherein:

FIG. 1 is an exploded front view of a typical installation of a horizontal mullion and a vertical mullion in the erection of a curtain wall wherein said mullions are formed with a nose portion;

FIG. 2 is a cross sectional view of a vertical or horizontal mullion of FIG. 1;

FIG. 3 is a perspective view of a first embodiment of the support bracket of the present invention for mullions of FIG. 1;

FIG. 4 is a front view of the support bracket embodiment of FIG. 3;

FIG. 5 is a front view of the intersection of a horizontal mullion and vertical mullion of FIG. 1 with the support bracket of the present invention positioned to support the horizontal mullion until its second end can be secured;

FIG. 6 is a perspective view of a second embodiment of the support bracket of the present invention;

FIG. 7 is a perspective view of another embodiment of the support bracket of the present invention for use in curtain wall installation when only the horizontal mullion is formed with a nose portion; and

FIG. 8 is a perspective view of a support bracket for curtain wall installation of one or two story height in which neither the horizontal mullion nor the vertical mullion is formed with a nose portion.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 through 6 illustrate a support bracket for erection of a curtain wall in which the vertical and horizontal mullions are formed with complimentary nose portions.

FIG. 1 is an exploded front view of a typical installation of a horizontal mullion 10 and a vertical mullion 12 and 12A in the erection of a curtain wall. Both mullions are fabricated from extruded aluminum and are generally rectangular in cross section defining a rectangular tubular inner portion 14 (See FIG. 2). On one surface of the mullion there is formed integral therewith a nose portion 16 which protrudes from the wall and when the curtain wall is fully constructed serves as the periphery in which a glass panel or a architectural panel would rest and be secured by means of a cover, pressure plate, and fastener (not shown). Certain curtain walls are erected of horizontal and vertical mullions having no nose portion or only a horizontal nose portion. The support bracket of the present invention is modified in accordance with FIGS. 7 and 8 to address these embodiments.

Positioned in spaced apart relationship along one or more lateral sides of the vertical mullion are shear blocks 20, the cross section of the shear block 20 conforming to the inner cross section 14 of the horizontal mullion. The shear block is secured to the vertical mullion by threaded fasteners 22 or other suitable fastening means. A first end 11 of a horizontal mullion 10 is then inserted over the shear block and threaded fasteners 24 or other suitable fastening means are utilized to secure the horizontal mullion to the shear block.

Typically, vertical mullion 12 is positioned and secured with the shear blocks 20 in their respective positions. The installers then insert a horizontal mullion 10 over each of the shear blocks 20 and secure it with a threaded fastener 24. The installers would then move to the location for the next adjacent vertical mullion 12A and position it in place and secure the opposing end 13 of the horizontal mullion 10 to a respective shear block 20A mounted on that adjacent vertical mullion 12A. The opposing end 13 of the horizontal mullion 10 would then be secured to the respective shear block 20A. Depending upon the size of the curtain wall, there may be a plurality of horizontal mullions 10 positioned between adjacent vertical mullions 12 and there may be a plurality of vertical mullions 12 spanning the distance for the curtain wall.

If the horizontal mullion 10 is of a short enough span, no undo sheer force occurs where the first end 11 of a horizontal mullion 10 is secured to shear block 20. However, if the horizontal mullion 10 is of a sufficient span, sufficient shear force is exerted on the shear block 20 prior to the second end 13 of the horizontal mullion being secured to the next adjacent vertical mullion 12A that the horizontal mullion can sag and come out of square. When this problem arises, the installer often requires an additional individual to support the second end 13 of a horizontal mullion 10 until it can be secured. This increases the labor cost of erecting the curtain wall. Still further, if the sheer force is sufficient enough, the first end 11 of the horizontal mullion 10 is pulled away from the vertical mullions creating spaces at joints and requiring additional installation time to correct the aesthetics of the installation.

FIG. 3 is a perspective view of a first embodiment of Applicant's installation bracket and FIG. 4 is a front view. In this design, the bracket 40 is L-shaped in configuration having a horizontal leg 42 and a vertical leg 44 in fixed 90 degree relationship. Horizontal leg 42 is formed of a U-shaped extruded aluminum member, forming a longitudinal channel 46 defined by its side walls 48, 50 and end wall 52 dimensioned such that it can be slid or fitted over the nose portion 16 of a horizontal mullion 10. The vertical leg 44 is comprised of a U-shaped extruded aluminum member which again defines a longitudinal channel 54 defined by side walls 56, 58, and end wall 60, which can be slipped or snap fit over the nose portion of a vertical mullion.

In this configuration (See FIG. 5), when the first end 11 of a horizontal mullion 10 has been secured to the shear block 20 on a vertical mullion 12, the installer snap fits the installation bracket 40 such that the vertical leg 44 snaps over the nose portion 16 of the vertical mullion 12 and the horizontal leg member 42 snaps over the nose portion 16 of the horizontal mullion 10, thereby providing additional support for the horizontal mullion 10 until the second end 13 can be secured to the shear block 20A of the adjacent vertical mullion 12A. For added support, an angled bracing member 62 is attached to the horizontal and vertical leg 42 and 44 at an angle. In this first embodiment, the horizontal leg and the vertical leg are formed of U-shaped extruded aluminum members having a channel on one side. In a second embodiment (See FIG. 6), the installation bracket 40A may be fabricated of extruded aluminum members having I-beam-like cross section such that there is a channel 46A and 46B and 54A and 54B defined on both sides of the horizontal and vertical leg 42A and 42B respectively. In this configuration, the installation bracket can be easily adapted to either a right hand or a left hand installation of a horizontal mullion to a vertical mullion. In either embodiment the respective U-shaped channels engage the nose portion of the mullion. In some instances the snap fit relationship is sufficient to maintain the bracket and horizontal mullion in position, however in some instances it is necessary to utilize a C-clamp or similar temporary securing device between the bracket and the mullion.

FIG. 7 is a perspective view of another embodiment of a support bracket for the erection of a curtain wall in which only the horizontal mullion is formed with a nose portion. The basic support bracket 70 is identical to the support bracket illustrated in FIG. 6 and utilizes the same respective reference numerals. The channel 46A would engage the nose portion of the horizontal mullion. Since the vertical mullion would have no nose portion, the bracket is adapted by securing a vertical plate member 72 to the vertical portion of the support bracket. In this configuration, vertical plate 72 is positioned in abutting relationship to the outside surface of the vertical mullion and the channel 46A can engage the horizontal nose piece. The bracket is maintained in position by a clamp means such as a C-clamp or the like between the vertical plate 72 and the abutting vertical mullion.

FIG. 8 illustrates the support bracket of the present invention adapted for the installation and erection of a curtain wall of the one story or two story variety in which neither the vertical mullion or the horizontal mullion is formed with a nose portion. The bracket 80 illustrated in FIG. 8 is similar in all respects with respect to the bracket 70 illustrated in FIG. 7 with the exception that an additional horizontal plate is now secured to the horizontal member of the support bracket. Additional horizontal plate 82 is secured to the horizontal portion of the support bracket. In this configuration, the vertical plate 72 is placed in abutting relationship with the outside surface of the vertical mullion. The horizontal mullion is secured to its shear block as described heretofore, and the horizontal plate 82 is clamped to the horizontal mullion abutting its underside surface. Once the horizontal mullion has been secured at its second end as described heretofore, the clamps securing the horizontal plate 82 to the underside of horizontal mullion and the clamp securing the vertical plate 72 to the outer side of the vertical mullion are removed and the bracket is removed for further use on additional mullion installations.

While the present invention has been described with respect to the exemplary embodiments thereof, it will be recognized by those of ordinary skill in the art that many modifications or changes can be achieved without departing from the spirit and scope of the invention. Therefore it is manifestly intended that the invention be limited only by the scope of the claims and the equivalence thereof. 

1. An installation bracket for the erection of a curtain wall wherein the curtain wall is comprised of a plurality of intersecting vertical and horizontal mullions, the vertical and horizontal mullions being formed with a longitudinally protruding nose member on one longitudinal face, which protruding nose member define a spatial area for receipt of a window panel or the like after the curtain wall is fully erected, the installation bracket comprising: a horizontal support member and a vertical support member secured in 90 degree relationship, said horizontal support member and said vertical support member defining a longitudinal channel accommodating a section of a nose protruding member of a secured vertical mullion and a section of a nose protruding member of a horizontal mullion having one end of which secured to said vertical mullion, said vertical support member of said installation bracket secured over said nose protruding member of said vertical mullion and said horizontal support member of said installation bracket secured over said nose protruding member of said horizontal mullion thereby providing support for said horizontal mullion while a second end of said horizontal mullion is being secured to an adjacent vertical mullion.
 2. The installation bracket for the erection of a curtain wall in accordance with claim 1 wherein said horizontal support member and said vertical support member are C-shaped in cross section defining a longitudinal channel accommodating a section of a nose protruding member of a secured vertical mullion and a section of a nose protruding member of a horizontal mullion having one end of which secured to said vertical mullion, said vertical support member of said installation bracket secured over said nose protruding member of said vertical mullion and said horizontal support member of said installation bracket secured over said nose protruding member of said horizontal mullion thereby providing support for said horizontal mullion while a second end of said horizontal mullion is being secured to an adjacent vertical mullion.
 3. The installation bracket for the erection of a curtain wall in accordance with claim 1 wherein said horizontal support member and said vertical support member are I-beam shaped defining two opposing C-shaped longitudinal channels, like facing channels on said horizontal support member and said vertical support member accommodating a section of a nose protruding member of a secured vertical mullion and a section of a nose protruding member of a horizontal mullion having one end of which secured to said vertical mullion, said vertical support member of said installation bracket secured over said nose protruding member of said vertical mullion and said horizontal support member of said installation bracket secured over said nose protruding member of said horizontal mullion thereby providing support for said horizontal mullion while a second end of said horizontal mullion is being secured to an adjacent vertical mullion.
 4. The installation bracket for the erection of a curtain wall in accordance with claim 3 wherein said installation bracket is reversible.
 5. The installation bracket in accordance with claim 1 wherein said vertical support member and said horizontal support member are further secured by means of an angled support arm secured angularly between said horizontal and vertical support member.
 6. The installation bracket in accordance with claim 1 wherein said horizontal support member, said vertical support member, and said angled support member are fabricated from extruded aluminum.
 7. An installation bracket for the erection of a curtain wall wherein the curtain wall is comprised of a plurality of intersecting vertical and horizontal mullions, the vertical and horizontal mullions being formed with a longitudinally protruding nose portion on one longitudinal face, which protruding nose portions defines a spacial area for receipt of a window panel or the like after the curtain wall is fully erected, the installation bracket comprising: a horizontal support member and a vertical support member secured in 90 degree relationship, said horizontal support member and said vertical support member being I-beam shaped in cross section and defining longitudinal slots accommodating a nose protruding portion of a secured vertical mullion and a nose protruding portion of a horizontal mullion having one end of which secured to said vertical mullion, said vertical support member of said installation bracket secured over said nose protruding portion of said vertical mullion and said horizontal support member of said installation bracket secured over said nose protruding portion of said horizontal mullion thereby providing support for said vertical mullion while a second end of said horizontal mullion is being secured to an adjacent vertical mullion.
 8. The installation bracket in accordance with claim 7 wherein said vertical support member and said horizontal support member are further secured by means of an angled support arm secured angularly between said horizontal and vertical support member.
 9. The installation bracket in accordance with claim 7 wherein said horizontal support member, said vertical support member, and said angled support member are fabricated from extruded aluminum.
 10. An installation bracket for the erection of a curtain wall wherein the curtain wall is comprised of a plurality of intersecting vertical and horizontal mullions, which define a spacial area for receipt of a window panel or the like after the curtain wall is fully erected, the installation bracket comprising: a horizontal support member and a vertical support member are of I-beam shaped construction defining two opposing C-shaped longitudinal channels, said horizontal support member and said vertical support member secured in 90 degree relationship, said vertical support member having selectively securable thereto, an extender plate in a vertical plane; said C-shaped longitudinal channels of said horizontal support member and vertical support member engageable with a nose protruding member of a horizontal mullion and a vertical mullion when said mullions are formed with said nose protruding member for support of said horizontal mullion; said extender plate of said vertical mullion in abutting clamped relationship with said outer surface of said vertical mullion when said vertical mullion has no nose protruding member and said C-shaped channel of said horizontal support member engages a nose protruding member of said horizontal mullion for support of said horizontal mullion while a second end of said horizontal mullion is secured to an adjacent vertical mullion.
 11. The installation bracket for the erection of a curtain wall in accordance with claim 10 wherein said horizontal support member has securable thereto, a horizontal extender plate for abutting clamp relationship with an underside of a horizontal mullion when said horizontal mullion has no nose protruding member thereby providing support for said horizontal mullion while a second end of said horizontal mullion is being secured to an adjacent vertical mullion.
 12. The installation bracket in accordance with claim 10 wherein said vertical support member and said horizontal support member are further secured by means of an angled support arm secured angularly between said horizontal and vertical support member.
 13. The installation bracket in accordance with claim 10 wherein said horizontal support member, said vertical support member, and said angled support member are fabricated from extruded aluminum. 